Pilot Plant “Germany I”

Renewable fuels are liquid or gaseous energy carriers that are not derived from fossil resources but from renewable sources. These include bio-based fuels (e.g. biodiesel, bioethanol, biogas) and electricity-based fuels (so-called e-fuels), which are produced using renewable electricity, hydrogen, and CO₂.

Synthetic, electricity-based fuels (e-fuels) can be used as e-gasoline, e-diesel, e-heating oil, or e-kerosene. They have the same chemical composition as their fossil counterparts and can therefore be used without restriction in existing engines as well as in the current logistics and refueling infrastructure.

Yes, most of them are bio-based fuels produced from plant or animal oils. The technical term for this is HEFA (Hydrotreated Esters and Fatty Acids). However, the available quantities are not sufficient to fully cover fuel demand. Some airlines, such as Condor, United, Alaska Airlines, and JetBlue, have set clear targets to use renewable fuels. Numerous offtake agreements have already been signed to support this. CAPHENIA and Condor are partners in such an agreement for the supply of sustainable aviation fuel.

More about the cooperation can be found in the press section.

SAF stands for "Sustainable Aviation Fuels" and is an umbrella term for sustainable aircraft fuels. There are a variety of feedstocks and processes used to produce SAF. What they all have in common is that they are nearly chemically identical to conventional kerosene, allowing them to be blended in any proportion with jet fuel – or even fully replace it. They are considered sustainable because they offer a significantly lower carbon footprint over their entire lifecycle (from raw material source to combustion) compared to fossil-based kerosene.

SAF can generally be divided into two main categories: BioSAF and eSAF.

These differ in terms of feedstock and production method. BioSAF is primarily derived from biomass such as plant oils, algae, or organic waste.

eSAF, on the other hand, refers to electricity-based synthetic fuels produced via so-called Power-to-X (PtX) processes, using CO₂ as a carbon source.

The unique aspect of the CAPHENIA process lies in its Power-and-Biogas-to-Liquid method. Electricity, biomethane, carbon dioxide, and water are integrated into a single process. This generates renewable aviation fuels, especially synthetic kerosene. The product stream consists of approximately one-third eSAF and two-thirds BioSAF.

This single process thus delivers two recognized pathways under the European classification system. It reduces complexity, speeds up implementation, and scales with renewable energy – while also utilizing regional biogas sources.

Taking into account current usage pathways and existing biomethane production, it is estimated that around 60% of the additional potential could be used for SAF. This corresponds to a significant, realistic SAF-compliant biomethane potential per year that can be harnessed without requiring additional agricultural land. As such, it could make an important contribution to the sustainable production of aviation fuels.

The European regulation ReFuelEU Aviation requires airlines and fuel suppliers to gradually increase the share of Sustainable Aviation Fuels (SAF) in air transport. Starting in 2025, at least 2% of aviation fuel must come from sustainable sources, rising to 70% by 2050.

To ensure compliance with these quotas, the EU has set strict penalties: fuel suppliers who fail to meet their targets must pay high fines of several thousand euros per ton of SAF not delivered. Airlines are also penalized per ton of sustainable fuel not used. These penalties make the continued use of fossil-based kerosene increasingly unattractive and create a strong economic incentive to switch to SAF.

Thus, sustainable aviation fuels are not only a key lever for climate protection but also a regulatory necessity. For CAPHENIA, this creates a stable market environment and growing demand for synthetic, CO₂-neutral aviation fuels.

Synthesis gas, or syngas, is a gas mixture consisting of carbon monoxide (CO) and hydrogen (H₂), and serves as a key feedstock for the production of synthetic fuels and chemical products.

It is generated through various processes from carbon-based materials such as biomass, waste, or CO₂, and forms the foundation for sustainable, CO₂-neutral fuels (e-fuels).

At CAPHENIA, synthesis gas is produced through an innovative and resource-efficient process that uses biogenic waste materials and CO₂ – making a significant contribution to the decarbonization of the aviation and chemical industries.